4 Wheel drive noise

[flautiger]

2003 4wd Expedition. With the vehicle in 2WD, the is a clatter, almost gear meshing sound. The dealer checked it and computer states no transmission problems. WHen the tranmission is put in AWD the noise go away. No noise in 4WDL and 4WDH. Dealer can not explain noise, just wants us to leave and they can check it out. Has anyone encountered this? Has 176000 miles

 

[MileHighMenace]

Hello, my 2004 does exact same thing. Did you ever find out the problem?

 

[MileHighMenace]

2003 4wd Expedition. With the vehicle in 2WD, the is a clatter, almost gear meshing sound. The dealer checked it and computer states no transmission problems. When the transmission is put in AWD the noise go away. No noise in 4WDL and 4WDH. Dealer can not explain noise, just wants us to leave and they can check it out. Has anyone encountered this? Has 176000 miles

OK I learned that it is caused by the IWE (integrated wheel end) solenoid there is a TSB out on it: 06-8-15 the part number is 6LZ9E441A they cost around $30 hope this helps!

 

[dginn69]

MileHighMenace, does that tsb cover expetions? It says 2004-2006 f-150 and Lincoln Mark lt. Changed the solenoid on my 04 still make the noise.

 

[MileHighMenace]

Yes, it worked for me and I have an 04 Expedition.

 

[dginn69]

Did you use the solenoid with the hood? Dealership said it was listed for expeditions but said I should use it.

 

[MileHighMenace]

Let me back track for a moment, this happened a few months back. I did get a new module (they only come hooded now) and it did not solve my problem. I rented a vacuum pump from Checker auto and tested my IWE (real simple test) and found it was my RF integrated wheel end was leaking vacuum and replaced it per the DIY here is the link. Very very easy job (2 hours) and problem solved.

http://www.f150online.com/forums/2004-2008-f-150/360269-iwes-removal-replacing.html

JP

 

[dginn69]

Thank you so much. I have seen that forum in my travels but was unsure if the f-150 was the same as the expedition. And I have the same issue as you, solenoid did'nt fix problem. Next step vacuum gage. Thanks again.

 

[MileHighMenace]

Get a vacuum PUMP with a gauge not just a gauge. Pull the hose/tube off the top of the IWE and pump out (create a vacuum) which will pull the IWE closed. Then if the vacuum bleeds off, you know you have a bad IWE(s)

 

[dginn69]

Thanks again I'll give that a try. I'm not sure how I feel about this 4x4 system, but what am I going to do? How hard was it to do the IWE? Does'nt seem too bad?

 

[MileHighMenace]

Very easy, and no alignment needed. Just print it out when you do it.

 

[dginn69]

Any special tools to pop the ball joints & tie rod ends? I'm a mechanic in the military and in Iraq we had a tool to pop the ball joints. Or will a BFH work OK?

 

[MileHighMenace]

Nope, no special tools needed. I used a plastic dead blow mallet. They really practically fall out!

Thank you for your service!

JP

 

[dginn69]

Your welcome. So the BFH(Big F**ckin Hammer)will work then? As soon as I get a moment I have to get that vacuum pump. In the mean time I'm driving in AWD. But I want to get this fixed. Where did you get you actautor? Online seems to be the cheapest. Thanks again.

Also I seem to hear a sound from the left hub upon starting. It almost sounds like a knocking, a friend jokingly said it sounds like a deisel. Could that be an indication of the IWE being bad?

 

[MileHighMenace]

I "borrowed" the vacuum pump from checker auto. The hose to the IWE is right on top of the hub, just pull it off, hook some tube to the IWE, draw out the air and watch the gauge ( I think you pump it to about 6 psi) to see if it bleeds off, check both sides. If the "diesel" sounding side holds vacuum, then you might have a bigger problem, maybe a bearing? Good luck.

JP

 

[dginn69]

Well as far as the bearing I dont think so. It only does it at start up sometimes and only lasts for a few seconds and the vehicle not moving. Then when driving uder light to med acceration I get the noise. Almost sounds like a pinging from cheap gas. Put it 4AWD or 4HI and it goes away. I'm pretty confident it's somewhere in the IWE system.

On another note there is a TSB for this problem. What does a TSB mean for the public? There is a sticky on one of the other discussions (pereformance & techical chat) and it says Ford should fix it at no charge. I find that hard to believe. Thanks again.


http://expeditionforum.com/showthread.php?t=2549

 

[jimmyv13]

Get a vacuum PUMP with a gauge not just a gauge. Pull the hose/tube off the top of the IWE and pump out (create a vacuum) which will pull the IWE closed. Then if the vacuum bleeds off, you know you have a bad IWE(s)

How long should the IWE hold pressure? I am seeing a slight drop over a few minutes form 10 inches to about 6 or 7 inches.

My solenoid checked out and is working properly.